How to Install a Boyesen SuperCooler

http://boyesen.com/
The primary purpose of this video is to illustrate to you how easy it can be to properly install the Boyesen Supper-Cooler yourself in the comfort of your own work space. Please feel free to view my video on YouTube explaining the benefits of the Boyesen Super-Cooler ( https://www.youtube.com/watch?v=1zKYt… ) and how it will help you “Win The War On Heat”.

Please note that some machines can vary from the current outlined procedure that I am using so please have the appropriate service manual for your model bike. The service manual will also provided you with detailed information pertaining to proper coolant required for your bike and any special torque values for fasteners.

Warning: Do not work on a HOT engine. Make sure the engine and coolant has had proper amount of time to cool down completely to reduce chances of serious burns or other injuries. Clean up any coolant spills immediately.

Bike Used: 2008 Yamaha WR450F

-Remove the protective skid plate (if applies) that could be in the way of the water pump.
-Place your bike on a suitable bike stand that will hold the bike upright.
-Some bikes may require the header pipe or expansion chamber to be removed to gain access to the hoses and or the water pump itself.
-I like to place shop towels or absorbent mats under the bike and on the shop floor to help catch any coolant that gets splashed.
-Remove the radiator cap. Push down and twist counter clock wise.
-Place a large clean container under the engine where the water pump is located to catch the coolant as it drains.
-Locate and remove the coolant drain bolt and allow the coolant to drain completely.
-Disconnect the coolant outlet hose(s) from the water pump housing. In this procedure the water pump has a metal coolant pipe that needs to be removed.
-Loosen and remove the water pump housing bolts. Please note a small amount of coolant may spill as you remove the water pump housing. Pay attention to what type of gasket seals the housing. Some bikes use an o-ring type seal that can be reused and other may have a paper style gasket which is not reusable. Some water pump housings use alignment pins so take care not to lose them.
-Remove the water impeller. Note some models may have a shim behind the impeller. Also usually the engine’s compression is enough to keep the crank from rotating during water impeller removal, if needed place the bike into gear.
-Install the supplied Boyesen Supper-Cooler water impeller with any washer/shims that were removed.
-Place the o-ring seal into the supplied Boyesen Super-Cooler housing or place the new gasket onto the engine cover allowing the alignment pins to hold the gasket in place.
-Install the Boyesen water pump cover and finger start all the retaining fasteners and even the coolant drain bolt. Lightly tighten all the fasteners then properly torque them to spec equally using a crisscross pattern.
-Re-connect any hoses or coolant pipes that were removed.
-If you had removed any exhaust pipes during this process you can re-install them at this time.
-If the coolant you drained into your clean catch pan was fresh/new then you can reuse it by pouring it back into the radiator fill using a funnel. If your bike was due for a coolant change then please refer to the service manual for coolant type and quantity.

Note: Most all new bikes found today have a self air purging coolant system while some may have an air bleed screw located on the cylinder head or other areas. Refer to your service manual.

-Fill the coolant to just below the filler neck and then re-install the radiator cap by aligning up the caps detents, push down and turn clock wise until it locks/stops.
-Start and run the bike for a few minutes, just long enough to get the bike up to temperature all while you check for coolant leaks.
-Turn off the bike and let cool, then remove the radiator cap and check coolant level and top off as needed.

Tips:
1. Use a high performance engine coolant when you can.
2. Using a high pressure radiator cap will increase the boiling point of the coolant.